Method and apparatus for making knitted pile fabrics



Feb. 14, 1961 J. HUBBARD 2,971,359

METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICS Filed July 25, 195712. Sheets-Sheet 1 FIG. I.

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INVENTOR JOHN L. HUBBARD 'BY 1mm ATTORNEYS Feb. 14, 1961 J. L. HUBBARD2,971,359

METHODZAND APPARATUS FOR MAKING KNITTED PILE' FABRICS Filed July 25,1957 12 Sheets-Sheet 2 N O O G o m 0 O O O O a m c w W \1 o o w o a wv\nv vm wv Q U I o Q w mm mm m. c 4 mm 3 a a 2:31.21... 9 w 5: in i;112:2: zm E4; 0 o u C m i vlllllll 6 O \h k: N \m 3158 0 Rm; @2293 mv om N 1% o o Q M M W .N M 2%. E o 1,. a 0 =8 an q E 0 EH can 8% 8m D a D 0O D o o o i o e um R .6 a a .8 B mw .B T illlllll m hm Q2 98 INVENTORJOHN L. HUBBARD BY M 1 m ATTORNEYS Feb. 14, 1961 J. L. HUBBARD 2,971,359

METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICS Filed July 1957 12Sheets-Sheet 3 H8 49 /o9 11a [/6 HQ y 9 U I35 (I; 8 a; a

au caw ac fi 49r ,A v 50 4a 5/ 45 \u 87 4;, s'h Eff 7 f T 435 43-1 25 soINVENTOR JOHN L. HUBBARD BY OMV'OL M ATTORNEYS Feb. 14, 1961 J. L.HUBBARD METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICS Filed July25, 1957 COURSE 0 l2 Sheets-Sheet 4 FIG. 4. COURSEb .5: '1 AMA M WW/WW1:), COURSEc i W -i/ 3: GOURSEd ii: ii? ii? iii w WARP WARP WARP WARPROWI ROW2 ROW3 ROW4 /50 m "w 7 V FIG. 5.

@ i M+I59m 1 N VENTOR JOHN L. HUBBARD BY MV M ATTORNEYS J. L. HUBBARD2,971,359

12 Sheets-Sheet 5 Feb. 14, 1961 METHOD AND APPARATUS FOR MAKING KNITTEDPILE FABRICS Filed July 25, 1957 FIG. 7.

INVENTOR a 9 w m JOHNL HUBBARD BY M 6 M ATTORNEYS Feb. 14, 1961 J. L.HUBBARD 2,971,359

METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICS Filed July 25, 195712 Sheets-Sheet 6 FIG. 5A

DWELL FOR NEEDLE MOTION SHIFTS BACKING WEFTS TO D SIDE 0 AM. TH AS ACROHR EE SPACES FIG. 8A.

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WARP MOTION DWELL FOR NEEDLE MOTION TS BACKING WEFTS AWAY FROM OF CAM.IN THI ASE ACROSS DWELL THREE NEEDLE SPA INVENTOR I" "||ll|||||||||||||||||l|| JOHN 1.. HUBBARD .200 RISK/Owin- BY ATTORNEYS Feb. 14,1961 J. HUBBARD METHOD AND APPARATUS FOR MAKING KNITTED FILE FABRICSFiled July 25, 1957 12 Sheets-Sheet 7 INVENTOR JOHN L. HUBBARD ATTORNEYSFeb. 14, 1961 J. L. HUBBARD 2,971,359

METHOD AND APP ATUS FOR MAKING KNITTED PILE FABRICS Filed July 25, 195712 Sheets-Sheet 8 JOHN L. HUBBARD BY 8 Q ATTORNEYS Feb. 14, 1961 J. L.HUBBARD ,971,359

METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICS Filed July 25, 195712 Sheets$heet 9 JOHN L. HUBBARD BY M ATTORNEYS Feb. 14, 1961 J. HUBBARD2,971,359

METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICS Filed July 25, 195712 Sheets-Sheet l0 IN VENTOR JOHN L. HUBBARD BY M ATTORNEYS Feb. 14,1961 .1. L. HUBBARD METHOD AND APPARATUS FOR MAKING KNITTED PILE FABRICSFiled July 25, 1957 12 Sheets-Sheet 11 INVENTOR JOHN L. HUBBARD M F MATTORNEYS Feb. 14, 1961 J. L. HUBBARD 2,971,359 METHOD AND APPARATUS FORMAKING KNITTED PILE FABRICS Filed July 25, 1957 12 Sheets-Sheet l2 1NVENTOR JOHN L. HUBBARD BY MI M ATTORNEYS FIG. 15.

United States Patent METHOD AND APPARATUS FOR MAKlNG KNITTED PlLEFABRICS John L. Hubbard, Cornwall-on-Hudsou, N.Y., assignor to The FirthCarpet Company, Inc., New York, N.Y., a corporation of New York FiledJuly 25, 1957, Ser. No. 674,142

Claims. (Cl. 66-84) This invention relates to the method of makingknitted pile fabrics and to apparatus adapted to this purpose.

Warp knitted pile fabrics are known in the textile art.

In order, however, to manufacture such knitted pile fabrics, not only ina solid color, but in variations of pattern, color and design, there areonly two known methods that have proven successful. One of these methodsof th: prior art involves the use of a Jacquard machine which is widelyused not only in the knitting art but also in the weaving art. The othermethodfor obtaining patterns and color variations in warp knitted pilefabrics requires the use of shifting bars which, in turn, are operatedin a sidewise, back and forth movement as outlined in the recent G. E.Herrnstadt Patent No. 2,718,132.

The present invention overcomes certain of the limitations oftheabove-mentioned prior art in the following respect: The use of theJacquard machine leaves a great number of face yarn ends afloat and,therefore, runs a lot of dead yarn into the fabric where they serve nouseful purpose to the consumer of the final product. Furthermore, theamount of colors and the extent of the pattern are inherently limited bythe Jacquard mechamsm.

In the second method mentioned above in which shifting bars are used,the pattern is limited more or less to geometrical designs and, sincethere is a limit to the number of shifting bars which can successfullybe used in a warp knitting machine of such type, the amount of colorsused within such geometrical patterns is also limited.

Therefore, it is a primary object of this invention to provide incooperative relation with a warp knitting machine additional mechanismadapted to make pile fabrics in which any design, no matter howintricate, may be reproduced in an unlimited color range Within suchdesign.

Furthermore, it is another obiect of this invention to provide a methodfor making pile fabrics on a warp knitting machine in an unlimiteddesign and color range whereby the pile height of such fabric is readilyvaried by several mechanical adjustments, as will be explained in alatter part of this specification.

Specifically, it is an important object of the invention to adapt a warpknitting machine to the manufacture of heavy pile fabrics, such ascarpet and the like, wherein the speed of making heavy pile fabrics inunlimited color and pattern range greatly exceeds that of any of themethods known heretofore.

Another purpose of this invention is to provide a method of forming piletufts within a warp knitting machine whereby the U of the tuft iscreated by warp ends zig-zagging between adjacent wales as they extendwalewise. I

Another object achieved by the present invention is the adaptation of aknown flat bed knitting machine without basic changes in itself tocombination with spool frames serving as tuft supplying units andthereby adapt- "ice ing the fiat bed knitting machine to the making ofpile fabrics without making basic changes in the knitting apparatus assuch.

It is a still further object of this invention to provide a novel methodfor making knitted pile fabrics without the usually necessaryproportional distribution of colors, Walewise and coursewise,respectively; and to afford a method which also provides the possibilityof distribution of tufts of different color, no matter how unlimited,between adjacent wales and successive courses, as may be desired.

A still further object of this invention resides in the method of makingcarpet on a knitting machine having the novel combination set forthherein, which carpet has all the advantages of woven fabrics, such asare known in the carpet art as chenille or Axminster carpeting, withoutlosing freedom of design and coloring in such carpeting, and at the sametime gaining speed in manufacturing by virtue of the inherent rapidityof the knitting process. For example, although chenille carpeting isknown as one of the finest of the soft surface floor coverings, both incolor and design as well as in quality, this product has lost a greatdeal of its popularity on the market because of the tremendous expenseof making it, requiring as it does a double weaving process. On theother hand, Axminster carpeting has been for many years one of theleaders in sales volume. It is from the art of Axminster weaving thatthere has been here adapted the overhead spool frames for combinationwith a knitting machine. The spool frames of the Axminster loom areessential to its commercial success because they provide prearranged andset color tufts distribution per pile row of carpet. However, Axminsterlooms have met more and more competition from the ever-improvingmechanisms of other carpet making methods. If fifteen pile rows ofAxminster carpet can be inserted per minute, it is considered high speedproduction. But the use of these spool frames in combination with a fiatbed knitting machine, as taught by the method of this invention, willincrease the speed of making carpet at least five times over the speedof the present Axminster loom, and at least twelve to fifteen times overthe speed of the chenille loom. Furthermore, the final knitted fabricwill equal in quality and appearance that of the woven fabric.

Therefore, it is another object of the invention to pro- Vide the feedof face yarn into the pile fabric from separate units, such as the spoolframes used in Axminster looms, said spool frames, in the case ofpatterned fabrics, being set according to prearranged design for eachpile row of repeat within a pattern. These spool frames are in usedipped in and out so as to provide a given length of pile tuft.

From the previous discussion it will be understood that the product ofthe invention is not limited to patterns and multiple colors alone, butmay be embodied as pile fabrics in solid colors. An advantage inemploying such spool frames for solid color pile fabrics resides in thefact that very often a great amount of yardage of the same color isrequired for the same run. Pile fabrics, as is well known, require morepoundage of pile yarn per square yard than fiat fabrics and there is alimit to the amount of yarn that can be dyed within the same dye lot. Inusing the spool frames in a knitted pile fabric for a solid colorproduct in large quantities, the setter of the spools can mix a numberof dye lots in such a manner that the various dye lots are distributedin different parts of the pile fabric, pile row by pile row, by whichpractice it is possible to avoid streaks or lines of any definitevisible shadings within the total yardage produced.

A still further object of this invention, especially for the carpetindustry, is the avoidance of the complications a ists 3and'liniitations of the Jacquard machine'in'combina'tion with a fiat bedknitting unitf Since most of the larger carpet mills have Axminsterspool frames, the combination of these spool frames with a warp knittingmachine, as provided by this invention, avoids the usage of Jacquardmachines. With Jacquard machines, designing requires technical skill.The threading has to be done in accordance with a pattern and,thereafter, cards have to be cut in order to bring those pile ends intomotion as required for each course and even then one is still limited inthe amount of colors used within a pattern.

An additional object of the invention is to provide a new combinationfor fine gauge pile fabrics, such as upholstery or the like, in whichspool frames of a finer gauge than in the carpet industry will beemployed, so that for the first time knitters of fine gauge pile fabricswill be able to engage in the production of expressive designs andcolors without the limitation of the shift bars and associatedmechanisms.

Still another object of this invention is the provision of a method andmechanism for the manufacture of pile fabrics on a flat bed knittingmachine provided with spool frames. This basic method and apparatuscombination enables the manufacturer of knitted pile fabrics to use theminimum amount of pile yarn for such pile fabrics and to predeterminethe usage of the pile yarn for such fabric by virtue of the fact thatevery tuft has a given length and that no pile yarn is wasted by runningdead, back and forth, or up and down, respectively.

The foregoing and other objects and advantages of the method andapparatus of this invention will be more fully understood from thefollowing detailed description ofthe preferred embodiment andmodifications thereof, when taken in conjunction with the accompanyingdrawings, in which:

Combination Figs. 1 and 2 taken together show a C0111- plete top planview of a warp knitting machine embodying this invention, certain partsbeing cut away for clarity, and the front of the machine being at thebottom and the back being at the top of these figures;

Fig. 3 is a vertical section of the machine of this invention, taken online IIIIII of Fig. l. and showing the pile yarn feeding, forming andcutting mechanisms in operative relation to the knitting needles andtheir drivingrmean's; Fig. 3A is an enlarged iongitudinal'section of theneedle bed and needle driving means;

'Fig. 4 is a partially diagrammatic top plan view of a novel fabric ofinterconnected construction that may be made in accordance with themethod'of this invention;

Fig. 5 is a partial side elevation of an end portion of one of the pileyarn supply and feed units;

Fig. 6 is an end elevational view of the unit of Fig. 5;

Fig. 7 shows an isometric end view of the drawing of pile yarn ends fromone of the units illustrated in Fig. 5, and indicates its use in theproduction of U-shaped pile tufts;

Fig. 8 is a further isometric view showing the backing weft guides abovethe needle bed and their relationship to the needle bed and the needles;

Fig. 8A is a face view of an enclosed cam for the weft motion; viewed online 8A-8A of Fig. 2;

Fig. 9 is another isometric view showing the backing Weft guides abovethe needle bed and the warp yarn guides in relations assumed in theinitial formation of a fabric constructed as shown in Fig. 4; and inwhich the weft guides have shifted to the right as a group, and withoutany pile yarns showing;

Fig. 10 is a further isometric view of a subsequent step in the sequenceof operations showing the diagonal extension of the warp threadsimparting a U-shape tothe pile yarn ends before cutting;

Fig. 10A is a face view of an enclosed cam for the warp motion; viewedon line 10A10A of Fig. 2;

Fig. 1-1 is an isometic view similar to Fig. 10 and showing thewithdrawal of the. utifi i a Completion of the sidewise extension of thewarp threads in forming a U-shaped tuft;

Fig. 12 represents a still further step in which opposed cutting bladesare advancing to sever the pile yarn ends;

Fig. 13 is a side elevation view partially sectioned of anotherinventive embodiment in which grippers are utilized for tuft insertion;and

Figs. 14, 15 and 16 show respectively in additional side elevationssuccessive steps in the operation of a modified form of gripper that maybe used for tuft insertion.

As shown in Fig. 4 the warp knit base fabric comprises stitches orstitch loops forming warpwise rows, or wales, 1, 2, 3, 4, and weftwiserows, or courses, a, b, c, a, and interconnected by portions of theknitted warp ends extending diagonally from each stitch to the twostitches in an adjacent wale located, respectively, in the two adjacentcourses, each knitted warp end thus extending forth and back in zig-zagfashion between two mutually adjacent wales. Inlaid threads w are alsoprovided, which undulate weftwise across several wales. Pile tufts t ofU-shape extend under and around the diagonally extending, stitchinterconnecting, portions of the knitted warp ends.

As shown in Fig. 1 and Fig. 2 combined, the knitting machine embodieswithin it Axminster type spool frames, and includes a rectangularframework 25, a plurality of longitudinally spaced frames 27, 29 and 31,and-end frames 33 and 35.

Power for operating the knitting machine is derived from a main driveshaft 37 extending adjacent and par allel to the back of the framework25 and driven by a belt-rotated pulley 59 as shown in Fig. 1. A needledrive shaft 41 lies above the main drive shaft 37, and a front warpshaft 42 is suitably supported for rotation near the front oftheknitting maehine. A front pile yarn cutting blade 43 (Fig. 3)operated by the front warp shaft 42 extends across the forward portionof the knitting machine, and a cooperating rear cutting blade 45 isreciprocated in opposition thereto by connection with the needle driveshaft 41. extending widthwise of the machine underlies the front cuttingblade 43; and another stationary guide 43 extending similarly and atanobtuse angle relative to the blade guide 47 underlies the rear cuttingblade 45.

A spool holding frame 4% extends longitudinally in parallel relationabove the front and rear blades 43 and 45, and their guides '47 and 48as seen in Fig. 3. In this same figure a weft bar 50 carrying aplurality of backing weft guides 51 is located immediately above aneedle guide bed 52, and backing weft ends are suitably fed thereto. Theweft bar 50 is given reciprocating and up and down movements by means ofa reciprocating and oscillating shaft 50s to which it is secured by arms50a integrally joined to collars 50c fastened to said shaft (Figs. 1, 2and 3). Warp stitch threads T are also suitably fed in a conventionalmanner and threaded through individual warp guides 59 such as areemployed in conventional flat bed knitting machines, and leadingtherefrom to respective needles located in needle bed 52 as indicatedgenerally in basic assembly 56, the pertinent parts of which are shownin Figs. 8 through 11.

The warp ends 111, 2a, 3a, 4a, 5a, 6a, 7a, etc., are threaded throughwarp yarn guides 59, etc., which are clamped individually to guide bar58 by resilient spring clips 60 of U-shape (Fig. 9). This warp yarnguide bar 58 is in turn connected with a bracket arm 62a (Fig. 3) forshifting sidewise movement back and forth by mechanism to be describedand in a manner to produce the novel pile fabric construction of Fig. 4.

Fig. 2 shows at the right end a common drive unit for the weft bar50 andthe warp yarn guide bar 58.

Two conventional bevel gear drives, 5? and 55, are taken from the backneedle shaft 41, whichis supplied with power from the main drive shaft37 through belt A stationary guide 47 v S 77, as indicated in Figs. 2and 3. The first of these drives 57 extends transversely between theneedle shaft 41 and the warp shaft 42 at the right of the loom frame 25,and the second drive 55 extends parallel thereto and provides a commontimed driving means for the related movements of the weft and the warpbars 50 and 58, respectively, as explained more fully hereinafter.

A backing weft shifting cam having a cam track formation provides apositive guiding means for a follower roller moving in an undulatingclosed path including spaced dwells of equal duration separated byarcuate segments of varying radii for shifting the backing weft guidesacross a plurality of needle spaces in one direction, and across a likenumber of needle spaces in the opposite direction during each revolutionof the needle drive shaft to which the shifting cam is geared for uniforrnly timed rotation and thus produces the required back and forthshifting of the bar carrying the weft guides and connected with shiftingrods.

The warp yarn shifting cam has a track formation receiving and guiding afollower means in an undulating closed path having a pair of opposedshort dwells and an opposed pair of long dwells with a short dropbetween along dwell and a short dwell, a long rise between said shortdwell and the other long dwell, a short rise between the other longdwell and the other short dwell, and a long drop between thelast-mentioned short dwell and the first-mentioned long dwell. Warp cam69 produces the timed sidewise motion of the warp yarn guide bar 58, thewarp yarn cam 69 being geared for uniformly timed rotation through across shaft 117 driven by needle shaft 41.

The novel construction and mechanisms of the combination of the knittingunits of the knitting machine with the spool frame will now beexplained, with particular reference to the arrangement as shown inFigs. 2 and 3. In these figures the backing weft guide bar 50 is locatedimmediately above the needle bed 52, and backing weft ends of jute orthe like are conventionally fed and threaded through each one of a setof weft yarn guides 51 of the fiat bed knitting machine. The warp yarnguide bar 58 is carried by the bracket arm 62a that is mechanicallyactuated to shift it sideways and back and forth in such a manner as toproduce a novel fabric construction as shown in Fig. 4. The warp guidebar 58 serves as a mechanism to lead a warp thread around the needles 53etc., as may be necessary in accordance with the fabric constructioninvolved. Below the bracket arm 62:: (Fig. 3) which carries the warpyarn guide bar 58 is the oscillatable front warp shaft 42 which operates1 said guide bar 58 through a plurality of spaced collars 64, eachhaving an integrally connected arm 64a, by means of which the warp yarnguide bar 58 may be reciprocated in timed relation to shifting of theweft ends by bar 54). A rod 65 to which the collars 64 are fixed movesthe warp yarn ends 1a, 2a, 3a, 4a, 5a widthwise of the knitting machineframework 25 in the manner shown in Figs. 9 and 10. This is accomplishedby means of the warp yarn cam 69 designated warp yarn cam in Fig. 2.

The needles 53 in this preferred form are operated by a plurality ofearns 66 of the enclosed type, which rotate with the needle drive shaft41. Each cam 66 operates a yoke bar slide 68 through a yoke bar slidefollower 70. As seen in Figs. 3 and 3A, the yoke bar slide 68 has a topyoke bar slide 72 and a lower yoke bar slide 74 which interconnects witha needle driver 76. While in some cases the needle drive shaft 41 may beoperated by the main drive shaft 37, it has been found that the strainin the case of wide looms, such as are used for broadloom carpets andrugs, can be reduced by having an additional shaft from which the needledrive shaft 41 is driven. For this reason there is shown as one of thepreferred forms the separate main shaft 37 having the belt rotatedpulley 39 for actuating the needle 6 drive shaft 41 through a belt 77.In Figs. 3 and 3A there are shown the parts of the loozn framework 25 onwhich the needle driver 76 and its needle driving bar 78 rest. Therearward end of the lower yoke bar slide 74 is supported and guided by apair of vertically spaced rollers 80, 80 suitably mounted on a part offrame 25.

It is preferred, as shown in Fig. 9, to use needles 53 that have apivoted latch L near the outer ends such as are Well known in the art.Between the needle driver 76 and the lower yoke bar slide 74 a hinge isprovided to relieve the strain, as it has been found that either part isapt to break in the absence of such a measure. The needles 53 are pulledbackwardly by a return pull member 87, which engages needle butts 53a ofeach needle (Fig. 3A). The return pull member 87 is interconnected bycap screws 88 to the needle driver 76 that pushes the needles in theforward direction.

In order to have a good takeup for the fabric itself as it comes off theloom, it is desirable to keep the fabric under as much tension aspossible. Therefore, in the preferred embodiment of the apparatus thereis provided an idler roller 100, which is well polished and mounted forrotation about a fixed horizontal axis, as shown in Fig. 3. The rollerleads the fabric downwardly as it comes from the needle bed 52 and witha reversing of direction onto a take-up roller 102. In accordance withthe fabric produced by the loom, the take-up roller 182 should either becovered with sand paper, card clothing or other rough, gripping materialthat will prevent slippage.

While there is but limited novelty in the knitting mechanism that hasbeen explained, subsequent reference to a consideration thereof will behelpful to a full understanding of the present invention which embodiesthe knitting mechanism as part of the inventive combination.

A plurality of like spool units 104, 104, 104, etc. are set into aparallel pair of endless and like lengths of sprocket chains 189 and110, each having spool length links 112 intermediate sprocket lengthlinks 114 that are longer than the spool length links 112 which carrythe spools. For simplification only a few of the spool units 164, 104,1434, etc. are shown in Fig. 3, but it is to be understood that as manyof these spool units are put on the chain length links 112, 112, 112,etc. as there are rows of couses of repeat and design required. Thespool units 164, 164, 104, etc. are carried forward mechanically by fourpairs of shaft mounted sprockets 116, 116, each of which has four endpoints or teeth 118. Each pair of said shaft mounted sprockets 116 istightly interconnected to a sprocket chain shaft 126, 127, 128 or 129.In Fig. 3 the upper left corner sprocket shaft 128 is positively drivenby the needle drive shaft 41 and rotates one-quarter turn as often perminute as there are courses. The mechanism for producing the one-quarterturns comprises a pinion gear 130 on sprocket chain shaft 128 disposedoutwardly of the adjacent sprocket chain 109, a larger intermeshingdriving gear 131 turning on a fixedly mounted stub shaft 132, a ratchetwheel 133 secured on the outer face of the intermeshing driving gear 131for rotation therewith and a pawl 134 pivoted on the outer end of an arm135 having its inner end mounted for relative pivotal movement on thestub shaft 132. A connecting rod 136 is pivotally connected by its upperend to the arm 135 and connected at its lower end with the needle driveshaft 41 so as to impart intermittently a partial rotation to theratchet Wheel 1313 sufficient to produce a one-quarter turn of thesprocket chain shaft 128 as required. For further details with respectto such spool units, see Coyle Patent No. 2,140,468.

It is now in order to explain in detail the, individual spool units 104,etc., which are specifically shown in drawings Figs. 3, 5, 6 and 7.These spool units 104, etc., while common and familiar to the art of rugand carpet weaving, are an innovation in the knitting field.

Each spool unit 104 consists of three main parts: First is a spool axle150 which extends from a spool body .152 into a bearing and spoolsupport 154, secondly a spool head flange 156 and its attachedmechanisms to hold it in place without unrolling, and finally, a tubeframe 158 with its attached tubes 159, etc. The spool body 152 with itsspool head or spool head flange 156 may be as long as desired. It ispreferably made of wood or light metaland the spool head flange 156should be strong enough to withstand the pressure of pile tuft yarnswhich are wound on it. For each space between the warp stitches one piletuft end PT will be wound on the spool body 152 (Fig, 7). The totalwidth of the spool body 152 will hold as many pile tuft ends as thereare spaces between the warp stitches and said tuft ends will bedistributed colorwise for one specific pile row, in the case ofapatterned and colored design, as the designers sketch may require. Ithas been found that the width of one spool should not extend to morethan 36 inches. Of course, there are fabrics which are woven in greaterwidths, such as certain upholsteries, in which one of the most desiredwidths is 54 inches, and floor coverings in which the width may extendup to 18 feet. In the case of the wider width looms used for thisinvention it is preferable to use a number of spool bodies 152 which arealigned in one row and interconnectible and on which the yarn is woundaccording to a predetermined pattern for each one of the spools andselected for a definite pile row in each course of the fabric. Whenusing the spool units- 154 certain things are of the utmost importance,such as the. steadiness of said units when they are' carried around'by.the chains until they are again selected for insertion of tufts in thefabric. When cylindrical units. such as these are filled with yarn, oneof the dangers is that the yarn induces a rotation of the spool body 152and thereby releases itself. A spring pressed (160.) spool brake 155secured from the tube frame 158 stops the spool body 152 from spinningfreely. At the end of the spool brake 155 the support 154 keeps thespool head156 in place. Also extending from the tube frame 158 are thespool axle 150, the spool support 154.and spring latches 163 and 164interconnected by pressure spring 166. By virtue of the spring latches163 and 164 the spool units 104 are attached to the spool lengths ofchain 109 and 110 (Figs. 1 and 2) and are held by the same. As will beunderstood from the above explanation, the spool unit 194 with its spoolhead flange 156 and its spool axle 150 are originally separate from thetube frame 158 with all its attachments. A plurality of individual andclosely spaced yarn tubes 159, etc. are attached to each tube frame 158.The yarn tubes 159 have at their respective upper ends a flared mouthformation 159m tapering toward the bottom of each tube.

In the preliminary setting yarn is put on the spool bodies 152, in tubeframes 153, and through tubes 159. The setters use various methods ofthreading the original face yarn ends, which have been previously woundaround the spool body 152 and inserted through the flared mouths 159mand the tubes proper 159. There is a deflnite reason for providing thetubes 159 with flared mouths 159m. It is often necessary to use knots inthe face yarn ends and, during the operation of the loom, these knotswill break as they feed into the tubes 159 if they do not have a chanceto work their way slowly thereinto through a flared mouth. This has beenproven in p the past'in Axminster looms and is a practical addition tothis invention.

The spool units 104 are either numbered or, in some cases, provided withflanges of different color so that the worker responsible for puttingsuch spool units into the spool lengths of chain pairs 109, 110, can doso by following a predetermined color arrangement.

Consideration will now be given to the operating means by. which thespool units 164 carrying the pile yarn ends 200 to 206 are dipped toinsert their attached yarn tubes 159 in between the warp ends 1, 2, 3,4, 5,

6, 7, etc. as illustrated. in Fig. 3 and Figs. 10 to 12.

drive shaft 41 as shown in Fig. 3.

to be connected between an intermediate part 49a of the upper horizontalpart of the framework and a cam follower plate 67 carrying a rollerfollower 67r engaging the single lobe plate. cam 66, which is turned bythe needle drive shaft 41. Therefore, in a one-course cycle of the100111 the set of yarn tubes 159 presented to the insertion and cuttingstation between the cutting blades 43 and 45, as shown in Fig. 3, willbe incorporated in the base fabric as U tufts, in accordance with Figs.9 and 10.

The tying in of the pile yarn ends by the warp yarn ends beforesevering, as shown in Fig. 12, makes it possible for predeterminedupward movement of the spool units 15d from their bottommost position todraw off the required length of pile yarn that, upon'severing, willprovide Ushaped tufts of uniform height.

After the spool units 104 are all in the respective pairs of chainlength links 112 and after the warp threads and the hacking wefts havebeen properly threaded, the method of making the desired knitted pilefabric can proceed.

To further explain this method reference is now made to Figs. 8, 9, 10,10A, 11 and 12 of the drawings.

Fig. 8 shows backing weft guides 51, 51a, 51b, 51c, 51d, 51c, 511, 51g,51h, 511', each positioned between adjacent needle "uides 54, 54a, 54b,54c, 54d, 54c, 54 54g, 54/2, 541', lying within the needle bed 52. Fig.8 also illustrates the preferred mode of inserting backing wefts w; Asmay be seen by close observation of this figure, the backing wefts, forexample, 11 are fed back and forth in successive courses across three ofthe needles 53. The needle bed 52 has within it needle guides 54 and thebasic assembly'of fiat bed knitting machine elementsis designated bynumeral 56.

By this procedure it is necessary only to thread one backing weftthrough each backing weft guide, such as 51, to obtain multiple results.The first of these is avoidance of running of chain stitches, which isso common in knitted fabrics, and the second is provision for more thanone backing weft per course without having to thread multiple backingwefts through the backing weft guides. This procedure is known in theart, as set forth in Herrnstadt Patent No. 2,7l8,l32. Depending on thetype of fabric to be made, this is, by way of example, an importantfeature of a pile fabric.

The kind of material to be used for the backing weft threads depends onthe type of fabric desired as the end result. In the case of floorcoverings, jute and paper threads have proved to be the most practicalmaterials since such types of materials have the additional property ofholding out the fabric and preventing shrinkage widthwise. in pilefabrics such as upholstery linen would serve the same purpose. butcotton, wool or some of the synthetic fiber threads may also be used.

Fig. 8 illustrates the initial steps in the method of manufacturing onefabric construction in accordance with this invention, and as shown inFig. 4.

Fig. 8 shows the tubular backing weft guides 51', 5111, etc., which arefirmly held in place by the weft bar 50 (Figs. 3, 9). In Fig. 11 thebacking weft guide 51 feeds a. backing weft thread 21w between needleguides 54a and 54b wherein is located needle 300 with its closed needlelatch L holding warp thread that is threaded through warp yarn guide 59dand is clamped by virtue of its resilient spring clip U 60 onto guidebar 58 (Fig. ll) carried by the bracket 62. (Fig. 3'). At the same timeit may be seen that the backing weft 21w is fed at this point by acorrespondingweft guide 51 (Fig. 11)

between needle guides 54:: and 54b within the needle bed 52 and thatsaid backing weft 21w extends across warp stitch 1 which is held byneedle 300 with its closed latch L. Backing weft 22w is fed from backingweft guide 51a between needle guides 54b and 540 and is bound in by warpstitches 1 and 2. Backing weft 23w is fed by backing weft guide 51bbetween needle guides I 54c and 54a and is bound by warp ends 1, 2 and 3held by the succeeding three needles 300, 301 and 302, with theirrespective latches L closed. Backing weft 24w is fed through backingweft guide 51c and the space between needle guides 54d and 542 withtheir respective needles 300 and their closed latches L. Backing weft25w is fed from backing weft guide 51d between needle guides 54e and 54and their respective needles 301 and 302 with their closed latches L.Backing weft 26w is fed from backing weft guide 51:: now in the positionbetween needle guides 54 and 54g with their respective needles 305 and306 and their closed latches L. At this point the needle 300 holds warpstitch from warp thread 1, needle 301 from warp thread 2, needle 302from warp thread 3, thread 303 from warp thread 4, needle 304 from warpthread 5, needle 305 from warp thread 6, and needle 306 from warp thread7. All these warp threads are guided by the warp yarn guides 59 on guidebar 58 wherein warp thread 1 is fed from creels or beams to needles 53in needle guide 54. As may be further observed from Fig. 11, backingweft threads 21w, 22w, 23w, 24w, 25w, 26w, 27w, etc., are to be bound inby the bights of the loops which needles 300, 301, 302, 303, 304, 305,306 presently hold. Fig. 9 merely shows the base fabric of backing weftscombined with a series of warp stitches, but without any pile yarninserted therein. As previously mentioned, this figure primarilyindicates the method for making the type fabric shown in Fig. 4.

In the next step, which is shown in Fig. 11 of the drawings, thefollowing takes place: Backing weft thread 21w, which prior to this stepwas positioned between needle guides 54a and 54b in backing weft guide51, now shifts to a position sidewise between needle guides 54b and 540.Backing weft 22w, with its guide 51a, now shifts from the prior positionto the right of needle 301 to the present position between needle guides54c and 54d. All other adjacent backing weft shift accordingly sidewiseacross as many needle guides (three) as described by the shifting ofweft guides 51 and 51a, since they are all stationarily set into theweft bar 50 to which the shifting mechanism A is attached. At the sametime, while the backing wefts move sidewise to their predeterminedposition as explained above, the tubes 159, etc. are dipped in betweenthe warp ends. The tube 159 carrying pile yarn end 200 is shown to clipbetween warp threads 1 and 2; pile yarn end 201 fed from the next ofsaid tubes is dipped between warp threads 2 and 3; pile yarn end 202 isdipped between warp yarns 3 and 4; pile yarn end 203 is dipped betweenwarp yarns 4 and 5; pile yarn end 204 is dipped between warp threads 5and 6; and the remaining pile yarn end 205 is shown dipped between warpthreads 6 and 7.

The next part of the preferred method of making one of the fabrics, asshown in Fig. 4, will be described in connection with Fig. 11 whereinthe guide bar 58 carrying the warp guides 59 moves in a directionopposite to the direction the backing wefts 21w, etc. have moved. Beforeproceeding further, it is to be observed that the sidewise movement ofthe warp threads, by virtue of the movement of guide bar 58, is notnecessarily in a direction opposite to the movement of the backing weftsby the guide bar 50. It is entirely possible that both the warp guidebar 58 and the backing weft guide bar 50 move sidewise in the samedirection. Nevertheless, it has been found that there is some advantageto moving them in opposite directions. One reason is that the variousparts are not forced in one direction and, therefore, produce a morebalanced action of the machine. Another reason is that, if the insertedpile tufts are not all intended to lie in one direction, it isadvantageous to make this movement of the bracket 58 in one sidewiseposition, first in one course and then in the opposite direction in thesuccessive course. While warp yarn guide 59 in Fig. 10 is aligned withneedle 300 by its connection with warp thread 1, it is by its rightsidewise movement, as shown in Fig. 11, being fed into the needle headof needle 301; and the needles 300, etc. have come out and opened theirlatches L to grab the following stitch. As the warp thread 1 moves fromits prior position opposite needle 300 to the right opposite needle 301,it puts a bend or a U into the face yarn end 200 by pushing it sidewiseand immediately thereafter it is being tied in by the retracting needle300 hooking warp thread 2. Thus it will be seen what happens in the pileforming process as in Fig. 11: Tube 159 moves upwardly between the sameneedle guide spaces 54d and 54a where it originally entered. But itspile yarn end 200, which prior to this was just dipped between the warpends 1 and 2, is being held by warp end 1 which now has been movedsidewise by the mechanism of the guide bar 58 which carries the yarnguide 59 for warp yarn 1. Warp yarn guide 59 is now tying in the pileend 201 with the help of warp end 2. The same operation is repeated forthe adjacent pile ends 202, etc. and the corresponding tubes 159. Theneedles 53 will now withdraw into the needle guides 54 in the needle bed52 with the help of the mechanism for the return pull member 87 (Fig.3A) and the latches L will close to drop the stitch of the prior courseand pull in the new stitch.

But one other step is necessary, namely, to cut off the length of thepile yarn ends 200, 201, etc. from the tube frames 158 so that the pileyarn is severed and can be carried forward with the remaining part ofthe fabric which has been formed. Therefore, for further simplificationof understanding of this invention there is shown one of the methods ofcutting off the pile yarn ends 200, etc., which are fed from the tubeframes 158 through the set of tubes 153. As explained hitherto, duringthe action of the course as described in Fig. 10, the individual pileyarn tubes 159 have moved upwardly to a predetermined position,depending on the length of pile tuft desired. In Fig. 12 there is shownone of the cutting means which has been most successful, namely, a frontpile yarn cutting blade 43 and a rear cutting blade 45 (Fig. 3). Therear cutting blade 45 is mounted on the back of the frame 25 as shown inFig. 3. Depending on the width of the machine there are as many bracketsor stationary guides 48 of the type shown, or similar types, as may beneeded for the width of a machine in order to keep the rear cuttingblade 45 as perfectly straight'as possible. The rear cutting blade 45has a ground edge and is operated by a rod 45-r pivotally connected atits rearward end to a pivotally mounted lever 45-1 having a followerroller 45- intermediate its length cooperating with a plate cam 45-0,driven by the needle drive shaft 41 in timed relation.

The front knife blade 43 also has a stationary guide or bracket 47, andis operated in like manner by a rod 43-r pivotally connected at itsrearward end. to a pivotally mounted lever 43-! having a follower roller43-7 intermediate its length cooperating with a plate cam 43-c turned bythe front warp shaft 42. The front pile yarn cutting blade 43 also has aground edge and is provided with as many brackets or stationary guides47 (Fig. 3) as may be necessary in a wide machine to keep the knifeperfectly level. It has been determined that the timing of the cuttingshould be such that it is accomplished immediately after the spoolholding frames 49 have been elevated to the predetermined positionnecessary to give This is' exactly what should takeplace now! The weft.

guides 51, etc. are in their downmost position andremain stationary toprovide clearing for the rear cutting.

blade or knife 45. The bracket 62a carrying warp'yarn guide bar 58bearing guides 59, etc. (Fig. 3) remains stationary also, at the lowestpoint, to provide clearance for the front pile yarn cutting blade orknife 43. The rear cutting knife 45 with its ground edge moves towardthe pile ends 2%, etc. below its tubes 159, etc. and goes in absolutelystraight. The front cutting knife 43 is moved forward towards the pileends 209, etcbelow its tubes 159, etc. to meet the edge of the backknife 45 with its front edge. The rear cutting blade 45 goes inabsolutely straight, laterally, and therefore requires the same type ofmechanical motivating means for as many brackets as it may have. Thepile yarn cutting blade 43 may be operated with slightly differenttiming from one end to the other end through mechanical means; it isthus possible to provide not only a cutting action by direct pressurewhen the edge of the pile yarn cutting blade 43 and the edge of the rearcutting blade 45 meet, but also a scissor-type action. It has been foundin wide machines that straight compression of blade edges is not aseffective as that obtained by giving one or the other knife ascissortype action. A different timing with mechanical means attached tothe brackets of front pile yarn cutting blade 43 provides such ascissor-type action in combination with the final compression actionupon total meeting of the edges of blades 43 and 45'. Such timing forprogressive cutting action widthwise of the machine is obtained byadjustment of the lengths of therods 43-! between the front blade 43 andther espective lever 43[ and the lengths of the rods 45-) and therespective levers 45-1. if these knife edges are made of material suchas tempered steel, grinding of the same would he required much lessfrequently, probably only once a month.

The backing weft shifting cam -53 as shown in Fig. 8A is provided with acam track formation 61 providing a groove receiving and positivelyguiding a follower roller 65; in an undulating closed path comprisingspaced areaare dwell segments of equal duration separated by modifiedarcuate segments of varying radii of like and cornpanion shape forshifting the backing weft guides 51 across three needle spaces in onedirection and three needle spaces in the opposite direction,respectively, during each revolution of the needle drive shaft 41, towhich the shifting cam 63 is geared for uniformly timed rotation througha cross shaft 115, as indicated in Fig. 2. The

shifting cam. 63 produces the required back and forth shifting of theweft bar 50 carrying the weft guides 51 through connection with theshifting rod 59:: (Figs. 2 and 3 The Warp yarn shifting cam 69illustrated in Fig. A has a cam track formation 71 providing a groovereceiving and positivey guiding a follower roller 691' in an undulatingclosed path comprising a pair of opposed short dwells and an opposedpair of long dwells with a short drop between one long dwell and a shortdwell, a long rise between said short dwell and the other long dwell, ashort rise between the other long dwell and the other short dwell and along drop between the last mentioned short dwell and the first mentionedlong dwell. The war yarn cam 69 acting on the roller 691' produces thetimed sidewise motion of the warp yarn guide bar 58 that is required byFig. 10 through connection with the shifting rod 65 (Figs. 2 and 3). Thewarp yarn cam 69 is geared for uniformly timed rotation through a crossshaft 117 driven by the needle drive shaft 41, as indicated in Fig. 2.

There has now been explained in detail the method of tuft insertion fora single complete course of a fabric construction such as shown in Fig.4. immediately after the cutting action takes place the back or rearcutting .blade 45 is withdrawn upwardly and rearwardly in order toprovide clearance forthe backing weft guides 51, etc.,

which :will" then be slightly elevated to shift the backing weft threads21w, etc. in a sidewise direction opposite to that'of the previouscourse. At the same time the front pile yarn cutting blade 43 retreatsto provide clearance for the dip of the spool'frame units 104 in thesuccessive, course. and also to provide a cutting sweep for the frontknife blade 43 itself. Furthermore, at the same time that the frontknife blade 43 and the back knife blade 45withdraw and, as thebackingweft guide bar Stl starts to shift sidewise, the chain sprocket shaft128 turns the shaft mounted sprockets 116 to carry another spool frameunit 164 upwardly and to move another spool frame unit 104 downwardlyinto place in time to be dipped between designated warp ends for thefollowing course. The only difference in the following course in theaction of pile forming for fabric construction as shown in Fig. 4 willbe that warp end 1 will move sidewise with the help of the shiftingmechanism (Fig. 10A) attached to rod 65, moving brackets 62a, etc. andwarp end 1 will again be opposite needle 3% after the course has beencompleted (Fig. 10).

It has been noted that the method illustrated in Figs. 7 through 12 hasbeen successfully used in making a fabric construction as shown in Fig.4.

As mentioned previously, the number of spool units 104, etc. useddepends on the number of courses necessary for a repeat within apattern. it cannot be stressed too strongly that this provision fordistribution of color and pattern is unique for a flat bed knitted pilefabric in which. the ordinary purpose is to draw the pile yarn from asupply which, is mounted independently on tube frames;

With reference to the spools and tube frames and their use in thesetting of pattern in more detail, it is noted this is generally oldart, as such. Skinner Patent 251,304 of 1881 shows the usage of spoolsin a weaving loom and further knowledge of the workings of such spoolswithin a loom or, of the setting of patterns and colors for such spoolsand tube frames may be derived from Dalkranian Patent 858,961 of 1907and Wyman Patent 454,414 of 1891, as well as Coyle Patent 2,140,468 of1938.

Although the preferred method of tuft insertion by dipping of the tubes159, etc. between the warp ends 1, 2, etc. has been explained, it hasalso been found that other methods taken from Axminster loom weaving canbe used successfully and, therefore, two more examples of tuft insertionwill be explained with. reference to Figs. '13, 14,15 and 16.

Fig. 13 shows the usage of a gripper unit which is often used in loomsof the Axminster type, called gripper looms. The pile yarn to thesegrippers may be fed either from sefected banks of a limited color range(not shown) or from the spool holding frames 49, shown as an example ofthis method in Fig. 13. Two different types of individual yarn grippersare shown in Figs. 13 and 15, respectively.

The gripper 469 comprises two gripper jaws, an upper gripper 'jaw 402and a lower gripper jaw 4&4 pivotally connected by a gripper jaw pivot4%. Each of the gripper jaws 402 and 404 extends .into its own mountingand activating parts, respectively, by being slidably connected at 408.The upper gripper jaw 402 extends into its body 410 wherein there is a Tslot 412 for mounting of the grippers individually. The lower gripperjaw 494 mates with its lever type body 411 and with its connecting leverhead 418 which is used to open and close the jaws of the gripper. Theopposed surfaces of the gripper jaws 402, 404 are preferably serrated atthe ends to pre vent slippage of the pile yarn ends which they areintended to grab and transfer into the fabric.

When using the type gripper shown in Fig. 13,.the tuft insertion of .thepile ends is made by a bank of grippers which extends laterally acrossthe width of the machine rather than by the dipping in and out of thespool unittubes (159) themselves. To further simplfy I the understandingof the operation of the loom combination of spool units and a fiat bedknitting machine wherein such grippers are used, Fig. l3 shows in dottedand full lines the action and steps that take place with the employmentof this type gripper. The pivot point for the gripper shaft 4% isarranged on a shaft 4-22. This shaft 422 performs the following steps inconjunction with a T bar 423: It moves forward towards the knittingoperator in front of the loom after having grabbed yarn from the tube159 by entering said tube and closing its jaws. The shaft 422 and the Tbar 4-23 move from point A to point B thereby withdrawing sufficientyarn from the tube 159 of spool unit 1334 to form one pile tuft. Aplurality of gripper units thus acting together form one row of piletufts. Thereafter, an upper knife 22% and a lower knife 221 out off thepile ends which are held by the gripper jaws. These knives 22d and 221work in much the same fashion as front pile yarn knife 43 and back pileyarn knife 45 work in Fig. 3. After the cutting of pile tufts, the T bar423 withdraws the gripper and lowers it in such manner that the gripperitself now locates its shaft 422 at point C. Thereafter, both T bar 423holding the grippers stationary in their T slot 412 and the mechanism(not shown} which activates the connecting lever head 418 turn through a90 degree angle around the pivot point marked 41? (Fig. 13) for thegripper shaft 422 and feed the pile tufts into the fabric, before theneedles S3 commence to form the stitch for the present course. As soonas the pile tuft has been bound in by the retracting needles 53 in themanner shown in a fabric in Fig. 4, connecting lever head 418 induceslower gripper jaw t'd l to open, to release the pile end 206), turn back90 degrees into its original position and move upwardly to point B toenter tube 159 of the following tube frame 15%; which is connected tospool holding frame 49 to repeat the same action in the successivecourse.

It has been found that the type gripper as explained in Figs. 15 and 16,when used in the carpet industry, may sometimes hinder proper operationof the knitting machine in combination with spool frames. The reason isthat in such heavy type machinery the gripper parts and their movingmechanisms prevent clear viewability by the operator of the machine.Nevertheless, the gripper action, as such, can sometimes be moresuccessful than the clipping of the spool units since it does notrequire the heavy work load. When dipping spool units between the warpends, as shown in Figs. to 12, the heaviness of the spool units candecrease the speed of the machinery. This would not be too difficult inthe case of such heavy fabrics as carpets and rugs since the heavinessof the pile yarn material and the backing weft material requires aslower working speed. But when one wants to weave finer pile fabrics anduse spool frames in order to get a multiple color and design effect, ashas previously been shown, this combination with gripper use affords amore speedy manufacturing process since it requires lighter parts forthe performance of quicker action. This is especially true of linevelvets, upholstery and even reproduction of tapestry.

Thus, it has been found that the gripper action is satisfactory incombination with the spool frames of the flat bed knitting machine butthat a more simplified gripper than the one generally known is required.For this reason another method of making pile fabrics from spool framesand one which is ample and satisfactory to make such fabricconstructions as shown in Fig. 4 has been evolved. As will be seen inFigs. to 18, there has been provided a gripper that is fairlystreamlined. This modified gripper has two serrated jaws, a back gripperjaw 224 and a front gripper jaw 225. Once again a pivot point 226 isprovided between the gripper jaws. The back gripper jaw 224- extendsbeyond the pivot point 226 to a mounting bracket 229, by which thegripper is adapted for attachment to elevating andlowering means 14 ofthe mechanical type. As shown in Fig. 14, warp end 1. is immediatelyalongside the upwardly moving gripper with its closed jaws. Thesegrippers actually enter between adjacent pairs of warp ends 1 and 2 andbetween as many spaces as there are between two adjacent warp ends fedfrom the warp yarn guides 59, etc. gripper in Fig. 14 the open-jawedgripper moves right into the tube 159, after which operating means (notshown) move activating lever 228 outwardly, thereby closing jaws 22d and225 onto the pile end which they have grabbedwithin tube 159 connectedto spool unit 104. This gripper works downwardly in three differentphases, but upwardly it only is operated from its lowest point to itshighest point, always entering between two adjacent warp ends guided bythe warp yarn guides 59. Fig. 16 illustrates how it has moved downwardlyfrom a high point to a low point.

After the gripper jaws 224 and 225 have closed and grabbed the pile yarnend from tube 159, it descends to its first position as shown in Fig.15. It should be kept in mind that the jaws 224 and 225 remain closedholding the pile yarn end which is about to be inserted into the fabric.But, the movement from the point where the jaws 224 and 225 originallygrabbed the pile yarn end to the point illustrated in Fig. 15 where ittemporarily stops serves two purposes: First the pile yarn end 260 isrolled off spool unit 1% to a given length predetermined for the pileheight within the knitted fabric. As the gripper lifting and descendingmeans attached to mounting bracket 229 temporarily keeps jaws 224 and225 at the point shown in Fig. 16, knives 43 and 45 cut off pile yarnend 200. This enables the sprocket shaft to pull the chain lengthsforward and to put spool unit 104 into place to supply the pile yarnends for the successive or following course.

Knives 43 and 45 are working in much the same manner as those shown inFig. 12. There is no difference between the knives as such, but thelocation of the knives 43 and 45 and their respective brackets areconsiderably above the backing weft guide units 51, etc., and the warpyarn guides 59, etc., as compared with the prior description in Fig. 12.In Fig. 15 the knives cut off the pile yarn ends 200 near the bottom ofthe tube 159 before the tube had been dipped into the spaces between theadjacent warp ends like in Fig. 12. In other words, it is the gripperwith the jaws 224 and 225 which replaces the dipping action of spoolholding frame 4%. This in turn gives more time to rotate the spool unitsTh4, etc., which motion can take place during the same period, rightafter the cutting operation in Fig. 15, while at the same time thegripper can perform its pile insertion action. After back knife 45 andfront knife 43 have cut off pile end 200, held by gripper jaws 22 iand225, the jaws remain closed as the gripper itself descends to the lowestpoint shown in Fig. 16. As soon as the gripper has been decended to thispoint, the warp yarn performs the binding-in action, of the pile end201), either by a sidewise movement as shown in Fig. l, or by theformation of a bight in parallel aligned warp stitches. As soon as thewarp stitches have been formed by warp ends 1, etc., the mechanismoperating activating lever 228 opens jaws 224 and 22S and brings thewhole gripper unit back to point as shown in Fig. 14.

The apparatus machinery and method of this invention is concerned withpile fabrics and primarily with such pile fabrics as are necessarilymanufactured on wide warp knitting machines. It has been found that agripper of the type as shown in Figs. 13, l4, l5 and 16 cansatisfactorily be made of light material, such as aluminum, magnesium orplastic. As many parts as are necessary on a wide knitting machine incombination with spool units, as described. should be made of lightweight materials for the simple reason that the less weight that has tobe brought into motion while manufacturing fabrics such as Like theshown in Figs. 4 and 11, the more number of courses per minute themachine may be operated. Since the invention resides basically in thenovel method of making a pile fabric by combination of two knownprocedures, the value of speed in manufacture is of paramountimportance.

In the present invention the tuft insertion itself is performed at thetime when a needle guide 59 wraps around warp ends 1. etc., and aroundthe needles 300, etc. (Fig. This takes place as follows: The pile end200 is inserted between the warp end and the needle which is now out ofthe needle guides 54d, e, g, with its latch open. Needle guides 59,etc., holding warp ends 1, etc., then swing around the needle 30%forming a loop and laying said loop of the warp yarn within the hook endof needle 300, etc. As the needle retracts the pile end is being boundin by either the bight of the stitch or around the warp yarn which hasbeen formed by a previously explained action of the warp yarn and thewarp yarn guides. After the pile ends 200, etc., have been cut off,tufts 30, etc. will be Within the fabric.

The construction disclosed has another advantage when, in looselymanufactured fabrics, a back sizing is applied.

Sizing of starch, rubber, polyvinyls and other known materials will givethese tufts a strong bind of adherence to the backing formed by thebacking Wefts w, a, b, etc. in combination with the Us of tufts 280,etc.

So far as spool frames are concerned it is emphasized that thecombination of spool frames and knitting machines as specificallydisclosed herein are especially adapted for the production of pilefabrics simulating such woven fabrics as are known as plush, velvet,chenille velvet, chenille carpeting and Axminster carpeting. While thisinvention is primarily directed to the production of cut pile fabricsand to knitting machines having a greatly varied capacity for design inunlimited color distribution, loop pile fabrics may also be made,although they will not have the same advantages of greatly varied designand multicolor.

In making a loop pile fabric only one tube frame is used and hooks orother pile forming means are provided for creation of the loop pile.

The yarns used for the pile ends of the fabrics referred to herein maybe of wool, cotton, rayon, acetate or other synthetic yarns, dependingprincipally on the type of fabric which is required in the end use ofthe consumer.

It will be apparent that many other changes and modifications may bemade in the apparatus and method as herein disclosed without departingfrom the principles of this invention. Therefore, this invention is tobe limited only as required by the prior art and the scope of theappended claims. i

What I claim as novel is:

1. In a machine for making knitted pile fabrics having pile tufts boundtherein, the combination comprising a flat bed warp knitting machineincluding means for interconnecting a weft backing with chain knittedwarps, a spool frame mounted over the bed of the knitting machine, and aplurality of grippers movably mounted to grip and withdraw individuallengths of pile yarn from a spool of the spool frame and to insert therespective withdrawn lengths of tuft yarn between adjacent warp ends.

2. In a machine for making warp knitted pile fabrics, the combinationcomprising a flat bed knitting machine, a spool frame mounted fordipping movement above the bed of the knitting machine, a plurality ofpile yarn feeding tubes extending downwardly from the spool frame, andmeans for dipping the spool frame'and the yarn feeding tubes in betweenthe warp rows.

3. The combination of claim 2 including blade means for cutting the pileyarn ends upon each dipping of the spool frame.

4. In a machine. for making knitted pile fabrics, the

combination comprising a needle bed. extending laterally across thefront of said machine, a plurality of latch needles operating withinsaid needle bed of said machine, a plurality of weft feeding andshifting tubes extending over the outer edge of the needle bed, anendless chain carrier..a plurality of pile thread spool units rotatablymounted on the carrier, a tube frame detachably attached to each spoolunit in longitudinally spaced relation, a transferring device for bodilymoving said spool units and presenting each unit in turn to a pile endinsertion position over the warp ends which are drawn toward the needlebed by said needles, means for manipulating the free end of each pilethread completely to loop it around at least one warp end drawn towardthe needle bed, a needle drive shaft, a cam mounted on the drive shaft,means interconnecting the needles with the drive shaft to drive andreturn the needles in the needle bed, means for holding the free ends ofthe looped pile threads above the ground warp threads during the tuftforming and stitching operation, and cutting means responsive tooperation of the needle drive shaft to cut off the inserted pile threadends from the tube frame.

5. In a machine for making knitted pile fabrics, the combinationcomprising a needle bed extending laterally across the front of saidmachine, a plurality of latch needles movable within said needle bed ofsaid machine, a plurality of weft feeding and shifting tubes extendingover the outer edge of the needle bed, an endless chain carrier abovethe needle bed, a plurality of pile thread spool units rotatably mountedon the carrier, a plurality of yarn feeding tubes attached to each spoolunit in parallel longitudinally spaced relation, a transferring devicefor bodily moving said chain carrier and presenting each spool unit inturn to a pile end insertion position over the warp ends drawn towardthe needle bed by said needles, means for manipulating the free end ofeach pile thread completely to loop it around at least one warp enddrawn toward the needle bed, a needle drive shaft, a cam mounted on thedrive shaft, means interconnecting the needles with the drive shaft todrive and return the needles in the needle bed, means for holding thefree ends of the looped pile threads above the ground warp threadsduring the tuft forming and stitching operation, and opposed bladecutting means responsive to operation of the needle drive shaft forsevering the pile thread ends from the yarn feeding tubes of the spoolunits.

6. In a machine for making knitted pile fabrics having pile tufts boundtherein, the combination comprising a fiat bed warp knitting machine, aspool frame mounted over and across the bed of the knitting machine, aplurality of pile yarn spool units rotatably supported on the spoolframe and having individual yarn feeding tubes extending therefrom,means for moving the spool frame toward and away from the bed of theknitting machine, and cutting means arranged to operate between the bedof the knitting machine and the yarn feeding tubes of individual spoolunits as said spool units are moved into position over the bed by thespool frame.

7. In a machine for making knitted pile fabrics having pile tufts boundtherein, the combination comprising a fiat bed warp knitting machine forinterconnecting a weft backing with chain knitted warps, a spool framemounted over and across the bed of the knitting machine, a plurality ofpile yarn spool units rotatably supported on the spool frame, aplurality of yarn feeding tubes extending outwardly from each yarn spoolunit, and a row of gripper units extending in parallel spaced relationwidthwise of the machine, each gripper unit having a pivotally connectedpair of jaws for gripping and withdrawing a yarn end from one tube of aspool unit, means for moving a spool unit toward and away from the bedof the knitting machine in timed relation course by course to bring theproper. pile yarn of a designated spool unit into inserting position asthe pattern may require.

